Disposable absorbent article with containment structure

ABSTRACT

A disposable absorbent article partially defined by a pair of longitudinally extending side edges and a pair of end edges extending between the side edges, includes a topsheet layer, a backsheet layer, and an absorbent core disposed between the topsheet and the backsheet. The disposable absorbent article also has a pair of side wall structures each having a pair of oppositely positioned end portions. A first side wall structure extends generally longitudinally between the core and one of the side edges and the other side wall structure extends generally longitudinally between the core and the other side edge. Further, an end strip constructed from an elastic material is positioned substantially adjacent each one of the end edges, and extends laterally between the side edges. Each of the end strips includes a fixed elastic end section disposed adjacent the end edge and secured to the topsheet, a fixed intermediate section positioned longitudinally inward of the fixed end section, and a movable, elastic inward section positioned longitudinally inward of the intermediate section. The fixed elastic section forms a waistband portion each of the front and back waist regions of the article. The intermediate section has a plurality of voids or apertures which are employed to substantially de-elasticize the intermediate section. The inward section includes a central portion spaced from the topsheet and the absorbent core, and a pair of side portions. These side portions are secured to the end portions of the side wall structures, thereby applying a contractile force between the side wall structures such the side wall structures (as well as the side edges of the article) are biased upwardly. The side wall structures and the inward sections are, therefore, secured to one another and disposed to define the sidewalls of a relatively deep containment pocket located in the crotch region.

The present application is a continuation application of applicationSer. No. 09/418,902 filed on Oct. 15, 1999 (now pending).

BACKGROUND OF THE INVENTION

The present invention relates generally to disposable absorbent articlessuch as a diaper, a training pant, or an incontinence pant.

Disposable absorbent article are increasingly popular products. Use ofdisposable diapers and training pants now exceeds, by far, the use ofcloth diapers. Further, advancements made in the design of disposablefeminine hygiene product have produced products which offer improvedcomfort and utility and, thus, the use of these products have alsoincreased. Advancements have also been made in the design of disposableadult incontinence products which are designed to control and absorbinvoluntarily bowel and bladder discharge associated with many medicalconditions.

Disposable diapers are designed with structural features intended toenhance fit, comfort, and/or minimize leakage. In this regard, variousstructural designs have been developed and incorporated into diapers.For example, disposable diapers may have standing inner leg cuffs whichare combined with elastic leg gatherers, such as the structuresdisclosed in U.S. Pat. No. 4,704,116 to Enloe, and in U.S. Pat. No.4,695,278 to Lawson. In these structural designs, the leg cuffs andelastic leg gatherers are designed to work together so as to retainwaste within a central core portion of the diaper. In another variation,a pair of “T”-shaped cuffs are disposed longitudinally on either side ofthe central core (see e.g., U.K. Patent Application No. 2,216,393)/

These prior art designs have been effective to varying degrees incontaining discharge from a wearer's body. The complexity in thesestructural designs also vary and may require multiple fabrication step.For example, cuff/elastic gatherer combinations require the creation ofboth a cuff and an elastic gatherer which must be separately applied andwhich must be engineered to work together. “T”-shaped cuffs generallyrequire additional engineering and manufacturing expense to place a“T”-shaped elasticized gasket upon a distal edge of a cuff. In analternate design that is disclosed in U.S. Pat. No. 5,643,243 to Klemp,a diaper is provided with elasticized unitary cuffs. Each unitary cuffincludes multiple strands of elastic material and provides the soleelasticizing means for containing waste within the crotch region of thediaper.

Many of these diapers and other garments are also designed with anhourglass contoured shape which improves the fit and comfort of thediaper. A disadvantage of such contoured garments is that their designgenerally requires the use of complex high precision machinery to formnecessary intricate shapes, thereby significantly increasing theproduction cost associated with the garment. Moreover, many of thesegarments are formed from rectangular absorbent articles, typically cutin assembly line fashion from moving webs. To form a garment from such arectangular piece of absorbent material, material is typically cut awayfrom the longitudinal edges of the absorbent article and discardedduring formation of the leg holes. While such contoured garmentsgenerally provide a more comfortable fit, these garments may be prone toleakage along the edges of the contoured region.

SUMMARY OF THE INVENTION

It is one of several features and objects of the present invention toprovide an improved disposable absorbent article.

It is another feature and object of the invention to provide at leastone such disposable absorbent article characterized by improvedcontainment capabilities and/or features adapted to minimize leakage.

It is yet another feature and an object of the present invention toprovide at least one such disposable article having a containment pocketfor the purpose of retaining body exudates.

It is yet another feature and an object of the present invention toprovide at least one such disposable absorbent article having astructure applicable to the waist regions of the article so as toprovide a waistband portion and/or a portion of a containment wall of acontainment pocket.

Therefore, in accordance with one aspect of the present invention, thereis provided a disposable absorbent article (e.g., a diaper, a trainingpant, etc.) having a pair of longitudinally extending side edges and apair of end edges extending laterally between the side edges. Theinventive article includes a topsheet layer, a backsheet layer, and anabsorbent core disposed between the topsheet and the backsheet. Thearticle further includes a pair of side walls, each of which has a pairof oppositely positioned end portions and an intermediate portiondisposed therebetween. A first side wall is positioned generally betweenthe core and one of the side edges and extends generally in thelongitudinal direction. A second side wall is positioned generallybetween the core and the other side edge, and extends also in thelongitudinal direction.

The inventive article also includes a pair of end strips (e.g., patch,material covering or similar structure), each of which is fixedgenerally intermediate the core and one of the end edges, and extendsbetween the side edges (e.g., laterally along at least a portion of thelateral distance between the side edges). Each of the end stripsincludes an elastic inward section that is spaced away from the topsheetand the absorbent core and has a pair of side portions. Each of theseside portions is secured to an end portion of one of the side walls,such that the side walls are biased generally upwardly. The end stripmay also finction to apply tension across the waist regions of thearticle and/or apply a contractile force between the side walls. Such anend strip may also be referred to as a tension strip or tensioner.

In accordance with another aspect of the invention, a disposableabsorbent article is provided having a containment pocket with a depthdimension. The pocket is disposed generally in the crotch region of thearticle and is bounded by a substantially continuous containment wallthat extends generally upwardly to retain exudates therein. Thecontainment wall has at least two elastic wall sections made preferablyfrom an elastic material and preferably distinct from the topsheet. Thecontainment wall also includes at least two intermediate wall sectionseach of which is disposed between one elastic wall section and anotherelastic wall section. Each of the elastic wall sections has a centralportion and oppositely disposed side portions and each of theintermediate wall sections has oppositely disposed end portions. Each ofthe side portions of the elastic wall sections is secured to an endportion of one of the intermediate wall sections such that theintermediate wall section is biased generally upwardly. In oneembodiment, the article includes an end strip generally secured to eachone of the waist regions. Each end strip includes an elastic inwardsection that is spaced away from the topsheet and the absorbent core toform one of the elastic wall sections of the containment wall.

In accordance with yet another aspect of the present invention, adisposable absorbent article is provided having at least one end stripthat is fixed intermediate the core and one of the end edges and extendsbetween the side edges (up to or short of the end edges). It should benoted that the end strip may be relatively wide or narrow and may have agreater or lesser longitudinal dimension than a lateral dimension. Theinventive end strip may include a first section that is preferablyelastic and preferably disposed adjacent the end edge (e.g., fixed alongthe end edge) and a second section disposed longitudinally inward of thefirst section (e.g., fixed to the topsheet). Together, the first sectionand the second section may be formed from the same materia (e.g., anelastic material). Also, these two sections may be referred to as thewaist section of the end strip. In one embodiment, the first section isformed from an elastic material and is secured adjacent the end edge toform a waistband portion of the article. The second section ischaracterized in that the first section is substantially more elasticthan this second section. Preferably, the second section is formed fromthe same elastic material as the first section and/or the rest of theend strip, but is substantially de-elasticized by providing a pluralityof voids, apertures, or slits therein.

The end strip of the inventive article also includes a third sectionpositioned longitudinally inward of the second section. This thirdsection has an inward portion that is spaced away from the topsheet andthe absorbent core (e.g., moveable). The third section is preferablymade from an elastic material and may be secured to longitudinallyextending side walls of the article (as described above) so as to applya contractile force between the side walls and/or bias the side wallsgenerally upwardly. In this way, the elastic inward sections and thegenerally upwardly biased side walls may form the substantiallycontinuous peripheral wall of a containment pocket disposed in thecrotch region of the article. In one embodiment, this third section isreferred to as a soffit section.

The depth dimension of the pocket may be defined as the verticaldistance between an inward edge of the inward portion and the averageelevation of the top surface of the core. This depth dimension ispreferably greater than about ¼″ and, more preferably, between about ½″and about 4″. Most preferably, the depth dimension of the pocket isbetween about ¾″ and about 2″.

Moreover, the side walls may be constructed such that an intermediateportion of the side edges generally parallel with (and spaced laterallyfrom) the core may be secured with the inward sections and is biasedgenerally upwardly. In one embodiment, the side wall includes such anintermediate portion of the side edges, a portion of the topsheet and/oran elastic member(s) (e.g., an elastic strand) secured to the side edgesand/or the topsheet.

Other and further objects, features, and advantages of the presentinvention will be apparent from the description provided herein ofpresently preferred embodiments of the invention, given for the purposeof disclosure, and taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a disposable absorbent article accordingto the present invention;

FIG. 2 is a top view of the disposable absorbent article in FIG. 1 in aflat, extended condition;

FIG. 3 is an exploded view of the disposable article of FIG. 1;

FIG. 4 is a cross-sectional view of the disposable article taken alongline 4-4 of FIG. 2;

FIG. 5 is a top view of a disposable absorbent article in a flat,extended condition according to an alternative embodiment of the presentinvention; and

FIG. 6 is a top view of a disposable absorbent article in a flat,extended condition according to yet another embodiment of the presentinvention.

DETAILED DESCRIPTION OF THE DRAWINGS

FIGS. 1-4 depict a disposable absorbent garment or article 10 embodyingthe invention. The disposable absorbent article 10 is of the type whichcan be placed against or in proximity to the body of a wearer so as toabsorb and to contain various bodily exudates. In particular, thedisposable absorbent article 10 depicted in the figures and, describedin more particular detail below, is in the form of a diaper 10. Itshould be noted, however, that the present invention is applicable to avariety of disposable absorbent articles and garments, includingtraining pants and a variety of adult incontinence products.Accordingly, the present invention is not intended to be limited to thestructures and the processes specifically described and illustratedherein. For purposes of description, the following discussion will bedirected to an exemplary disposable diaper only.

In addition, the invention will be described in the context of itsvarious configurations and aspects. It should be appreciated thatalternative arrangements of the invention may comprise variouscombinations, which include one or more of the various configurationsand aspects of the invention.

FIG. 1 illustrates, in perspective view, a composite web structure ofthe diaper 10 in a generally flat and unfolded configuration which itassumes during one point in the manufacturing process (when it isstretched in the longitudinal direction). As will be explained furtherbelow, the web structure may be subsequently trimmed, folded, sealed,welded and/or otherwise manipulated to form a disposable diaper 10 in afinished or final form.

To facilitate description of the diaper 10 embodying the invention,description will refer to a longitudinally extended axis AA, a laterallyextending central axis BB, a pair of longitudinally extending side edges90, and a pair of end edges 92 which extend between side edges 90. Alongthe longitudinal axis AA, the diaper 10 includes a first end region orfront waist region 12, a second end region or back waist region 14, anda crotch region 16 disposed therebetween. Each of the front and backwaist regions 12, 14 is characterized by a pair of ear regions or ears18, which are located on either side of a central body portion 20 andextend laterally from the side edges 90. A fastening structure 26 (e.g.,a conventional tape fastener) is affixed to each of the ears 18 alongthe back waist region 14 of the diaper 10.

As shown in the Figures, the diaper 10 is characterized by a generallyhourglass shape wherein an intermediate portion of the side edges 90(which is generally in the area of the crotch region 16) is biasedgenerally upwardly (i.e., to partially form upwardly disposedlongitudinal walls). When the diaper 10 is worn about the waist of thewearer, the front waist region 12 is fitted adjacent the front waistarea of the wearer, the back waist region 14 is fitted adjacent the backwaist area, and the crotch region 16 fits about and underneath thecrotch area. To properly secure the diaper 10 to the wearer, the ears 18of the back waist region 14 are brought around the waist of the wearerand toward the front and into alignment with the ears 18 of the frontwaist region 12. This securing surface may be located on or provided bythe interior or exterior surface of the front waist region 12.Alternatively, the fasteners 26 may be located on the ears 18 of thefront waist region 12 and made securable to the ears 18 of the backwaist region 14. In one further example, a tab structure having hookstructures may be attached to the ears 18 of the waist region 14 andmade securable to loop members found on the front waist region 12. Sucha “hook and loop” concept (and other generally known fasteningstructures) is generally known and practiced in the art and may beincorporated into the present invention design by one skilled in the arthaving access to the disclosure provided herein.

The diaper 10 of the present invention also features one or morelongitudinally stretchable elastic members or leg elastics 32 positionedadjacent each of the two side edges 90 of the diaper 10 (see FIG. 3).When the diaper 10 is properly worn by the wearer, each leg elastic 32encircles a leg of the wearer and provides a quasi-seal thereabout whichsubstantially prevents leakage from the interior of the diaper 10. Suchleg elastics 32 may be applied in the stretched or extended condition.In one application of invention, the elastics 32 are placed between thetopsheet 50 and the backsheet 40 in the stretched condition, and, then,attached to one or both of the sheets 50, 40 (i.e., by glue or otheradhesive). When subsequently released, the elastics 32 retract and formbarrier cuffs, gathered leg regions or leg gatherers 36 as it pullsadjacent material therewith (see also FIGS. 1 and 2).

Now referring primarily to the exploded view of FIG. 3, a diaper 10according to the invention typically features two to five layers. Thesefive layers include a non-woven backsheet 40, a film barrier 42, a core46, a topsheet 50, and a pair of end strips or tensioner members 80disposed above the topsheet 50. FIG. 4 provides a cross-sectional viewthat depicts all five layers and their respective structuralrelationships. In an alternative embodiment, the diaper 10 may includean acquisition layer disposed between the core 46 and the topsheet 50(such a construction is described in more detail below). In yet anotherembodiment, the inventive diaper may utilize a multipurpose material asone of the layers (which provides multiple functions). In this way, thenumber of layers that is required may be reduced, and, in someembodiments, a thinner diaper structure results.

The tensioner member or tensioner 80 is preferably a single pieceelastic strip having an outside end edge 82 a, an inside end edge 82 b,and a pair of opposite side edges 82 c. As shown in FIGS. 2 and 4, thetensioner 80 is disposed over the surface of the topsheet 50 such thatthe outside end edge 82 a is secured adjacent (e.g., aligned with) theend edge 92 of the diaper 10 (i.e., at each of the front waist region 12and the back waist region 14). In the embodiment of FIGS. 1-4, thetensioner 80 generally extends transversely between the ears 18, i.e.,from adjacent one side edge 90 of the diaper 10 to adjacent the oppositeside edge 90. Along the longitudinal direction, the tensioner 80 extendsinwardly from adjacent end edge 92 toward the crotch region 16 and justover the area of the core 46 (at an angle direction spaced from the core46 and topsheet 50). Thus, the tensioner 80 occupies a substantialportion of the front waist region 12 or back waist region 14 except inthe ear regions 18.

The tensioner 80 may be formed from elastic film, foam, a combination ofnon-woven material and a stretchable film that is laminated together ora combination of two or more of these materials or laminate. Thetensioner 80 may also be formed from a non-woven material with elasticstrands or elastic non-woven material. In one suitable construction, thetensioner is formed primarily from an open cell polyurethane foamavailable from General Foam of Paramus, N.J. In yet another suitableconstruction, the tensioner is formed from an elastic apertured filmavailable from Tredegar Industries of Cincinnati, Ohio.

The tensioner 80 is preferably comprised of at least three distinctsections: a fixed elasticized section 80 a preferably secured adjacentone of the end edges 92 of the diaper 10, a fixed de-elasticized section80 b which extends inwardly (in the direction of the crotch area 16)from the elasticized section 80 a, and an elasticized soffit section 80c which.extends inwardly (in the direction of the crotch area 16) fromthe de-elasticized section 80 b. In the flat, extended condition of thediaper, as shown in FIG. 1, there is a vertical separation or verticaldistance CC between the inside edge 80 d of the soffit section 80 c andthe top surface of the core 46. Both the fixed elasticized section 80 aand the fixed de-elasticized section 80 b are secured (using any one ofa number of securing means known in the art, e.g., by melting, sonicmolding, or by applying adhesives) to a top surface of the topsheet 50.

Preferably, the tensioner 80 is secured to the top surface of thetopsheet 50 while it (the tensioner 80) is disposed in the stretchedcondition and such that, when the secured tensioner 80 is subsequentlyreleased, the fixed elastic section 80 a contracts with the adjacentportion of the front or back waist region 12, 14 intact. This forms astructure that provides the same functional advantages as a traditionalwaistband along the end edges 92 of the diaper 10. Accordingly, when thetwo end edges 92 are joined around the waist of the wearer, the twofixed elastic sections 80 a are also joined and function generally aswaistbands to secure the diaper 10 snugly around the waist of thewearer. Moreover, the two fixed elastic sections 80 a form a quasi sealaround the waist of the wearer to prevent waste captured by the diaper10 from leaking past the top or end edges 92.

The de-elasticized section 80 b is formed with a plurality of voids orapertures 98 each of which functions to de-elasticize the immediate areaadjacent the apertures 98. Collectively, the plurality of apertures 98function to substantially de-elasticize the elastic material of thede-elasticized section 80 b. The apertures 98 are typically created byslitting or cutting that section of the tensioner 80 at a stage in themanufacturing process before application of the tensioner 80 to the topsheet 50 or other subsurface layer. The size and number of apertures 80are determined so as to prevent unnecessary weakening of the tensioner80 and to guard against propagation of tears in the de-elasticizedsection 80 b. Alternatively, de-elasticization is achieved by a heatdeformation process which de-elasticizes the elastic material byapplying heat on the targeted material before application of the tension80 to the topsheet 50 or other subsurface layer. In other embodiments,de-elasticization is achieved by the addition of stiffening materials atthe targeted area. In further embodiments, other methods ofde-elasticization known to those skilled in the art are utilized. Oneadvantage provided by the existence of a de-elasticized or non-elasticsection is that the end strip can have elastic properties but thetendency of waist regions to contract (i.e., in the longitudinaldirection) or crumple up is minimized.

It should be noted that the de-elasticized section 80 b and the fixedsection 80 a are referred to herein as two sections of the tensioner 80(e.g., a waist section of the tensioner 80) only for descriptivepurposes. However, in the embodiment depicted in FIGS. 1-4, the fixedelastic section 80 a and the fixed de-elasticized section 80 b areformed from the same elastic material and differ only in that thede-elasticized section 80 b has been applied and configured with theapertures 98. In alternative embodiments, these two sections may,indeed, differ substantially structurally and/or from a manufacturingstandpoint.

Absent of voids or apertures, the soffit section 80 c of the diaper 10depicted in the drawings retains the strength and elasticity of theelastic material from which the tensioner 80 is formed. The soffitsection 80 c may also be referred to as the inward section of thetensioner 80. In FIGS. 1-4, the sofftit section 80 c is also formed fromthe same elastic material from which the fixed elastic section 80 a andthe fixed de-elasticized section 80 b are formed. The soffit section 80c extends inwardly from the de-elasticized section 80 b and upwardly(i.e., at an angle) away from the topsheet 50. As best shown in thecross sectional view of FIG. 4, the soffit section 80 c extends inwardlyto the extent that it is over a longitudinal edge portion 46 a of thecore 46.

In one aspect of the invention, substantially all of the central portionof the soffit section 80 c is free from and is spaced from the top sheet50, while the side portions or lateral edges of the soffit section 80 care secured to the top sheet 50 and the distal edges 36 a of the leggathers 36. As a result, the tensioner 80 functions to pull at least theintermediate portions of the. side edges 90 or, more appropriately, theregions of the side edges (including the leg gathers 36) upwardly (byapplying a contractile force across the waist region 16). These sideedge regions are biased or brought to and maintained in an upstandingposition along the crotch region 16 (see, e.g., FIGS. 1 and 3), to formupright side wall structures or side walls. As will be further explainedbelow, these upstanding wide walls perform a containment or sealingfunction, as well as enhance the fit and comfort of the diaper 10.

As best shown in FIG. 1, the diaper 10 takes on an hourglass shape thatis particularly advantageous to the fit and sealing ability of thediaper 10. This fit is further enhanced by the upstanding disposition ofthe leg gathers 36 (provide side walls) and the tension provided in thefront and back waist regions 12, 14 by the tensioner 80. Anotheradvantage provided by the inventive diaper design is that the hourglassshape of the diaper may be attained without having to cut leg openingsinto the composite web structure during the manufacturing process.

In yet another aspect of the invention, the combination of theupstanding side walls (including the barrier cuffs or leg gathers 36)and the elasticized soffit section 80 c on both the front waist region12 and the back waist region 14 of the diaper creates a retentioncompartment or containment pocket 96 at the crotch section region 16.This retention compartment 96 is generally deeper than conventionalcontainment or central core areas. The retention compartment 96 may becharacterized as having a depth dimension generally equal to thevertical distance CC or the vertical distance between the inward edge 80d and the average elevation of the top surface of the core 46. Thisdepth dimension CC is generally greater than about ¼″ and up to about4″, but preferably will be between ¾″ and 2″ (as measured when thediaper 10 is in the flat, extended condition). The upstanding leggathers 36 serve as one set of retaining sidewalls for the retentioncompartment 96 while the oppositely-facing elasticized soffit sections80 c serve as retaining end walls of the retention compartment 96. Theelasticized soffit sections 80 c are, in one regard, particularlyadapted to provide such a function because it extends upwardly and wellabove the core 46. Thus, the retention compartment 96 may be referred toas having at least two elastic wall sections and at least twointermediate wall sections each disposed between elastic wall sections.In alternative embodiments, the wall sections may be disposed in otherareas of the article 10. The relatively deep retention compartment 96 ofthe present invention provides an improved structure and means forreceiving and retaining body exudates in the central portion of thediaper 10. It should be noted, however, that the design of a deepretention compartment 96 is also applicable and advantageous in otherdisposable articles or garments 10.

In alternative embodiments of the present invention, the end strip mayconsist of more or less than three distinct sections. Further, thesections of the end strip may not be necessarily formed from the samematerial. Further yet, the end strip may be formed integrally as onepiece with the topsheet or may include a portion of the topsheet.Additionally, the end strip may not necessarily be disposed adjacent theend edges and, in partially forming a containment wall of a retentioncompartment, may not necessarily be disposed in the front or back waistregions of the article. Some of these variations are discussed below.However, it should be noted that these variations or adaptations will beapparent to one skilled in the art upon reading the description andviewing the drawings provided herein.

In one alternative embodiment of the present invention, the tensionerconsists of only the soffit section. Such a soffit section may be formedfrom an elastic material or a composition including an elastic material(e.g., elastic film or elastic strand(s)). The soffit section may bewholly elastic or include a portion having elastic properties. Forexample, the soffit may include a central portion that is formed from anelastic material (or otherwise elasticated), and side portions which aresecured to the ends of barrier cuffs, leg gathers or portions of theside edges (so as to create upstanding side edge regions or side walls).Further, the soffit section may be formed by creating a fold with aportion of the topsheet and by elasticating at least a portion of thefold.

In yet another alternative embodiment, the disposable absorbent articleaccording to the invention may include a traditional waistbandstructurally separate from the end strip and/or soffit section. Such adiaper may also include a non-elastic or de-elasticized section betweenthe waistband and the soffit section. Further, such a non-elastic orde-elasticized section may be integrally formed with the soffit section.

In yet another embodiment, an end strip according to the invention isdisposed one each lateral side of the core. Such an end strip includesan elastic or tensioned portion and may be formed, at least partially,with the topsheet and/or barrier cuffs or leg gathers. The end stripincludes side portions which are secured to a side wall structure whichmay be formed from a folded portion of the topsheet, so as to bias thefolded portion upwardly. Accordingly, a containment pocket of thedisposable absorbent article is formed having a generally upwardlydisposed and substantially continuous peripheral wall that is providedby the end strips and the side walls.

It should be further noted that, by locating an end strip at certainlocalized regions of the article as in the various embodiments describedabove, a tensioned or contracting zone is created in those regions. Thetensioned zones provide one or more functions including providing aportion of a containment wall of a containment pocket. The tensionedzones may also function to bias generally upwardly a structure disposedadjacent each end of the tensioned zone such that the structures formside walls of the containment wall. In some embodiments, the tensionedzones also form a waistband portion.

FIGS. 5 and 6 each depict a plan view of an alternative embodiment ofthe invention having a tensioner 80′, 80″ that forms one portion of thecontainment wall of a retention compartment or containment pocket 96′,96″. In the embodiment depicted in FIG. 5 , the diaper 10′ employs atensioner 80′ having a fixed elasticized section 80 a′, a fixedde-elasticized section 80 b ′, and a movable soffit section 80 c′. Onefeature of this diaper 10″ is a tensioner 80′ that extends laterallyover the ear regions. This side portion may be die-cut to form, alongwith the topsheet and/or the backsheet, a stretchable ear region or sidepanel 18″ of the diaper 10′. The diaper 10″ of FIG. 6 employs anotherend strip or tensioner 80″ consisting of a soffit section 80 c″. Thesoffit section is fixed on one edge to the topsheet 50″ and extendsimmediately inwardly therefrom and away from the topsheet 50″.

The following discussion expands upon the description of certaincomponents described above which may be incorporated into a disposableabsorbent article according to the invention:

Backsheet and Film Layer

A backsheet employed by a disposable absorbent article according to theinvention may be constructed from a number of different suitablematerials and, preferably, will have a breathable or vapor permeableattribute (distinguishing it from a liquid permeable material) such thatair can pass therethrough. For example, the backsheet may be formed froma combination of a liquid permeable, nonwoven material and a filmbarrier that is laminated onto the nonwoven material. This type ofbacksheet design is in contrast to the design employed by the embodimentof FIGS. 1-4, wherein the backsheet 40 and the film barrier 42 areseparate and distinct from one another. In either design, the filmbarrier may or may not be vapor permeable.

One construction suitable for incorporation with the design of thepresent invention, and more particularly, for the backsheet includes anouter layer of spunbond polypropylene fiber with a basis weight of about14-25 grams per square meter (available from BBA nonwovens, ofSimpsonville, S.C.) and a polyethylene film of about 0.5 mil. (0.0005inches) thickness adhesively laminated to the outer layer. Such apolyethylene film is available from, and manufactured by TredegarIndustries of Cincinnati, Ohio. This film may be laminated usingadhesive available from National Starch and Chemical Company ofBridgewater, N.J. Yet another suitable construction for the backsheetincludes a web of spunbond or SMS (spunbond/meltblown/spunbond) nonwovenmaterial and a breathable or nonbreathable film(s) of 0.5 mil. to 2.0mil. thickness.

The backsheet covers at least the core 46, but preferably extendslaterally beyond the core toward the side edges and the end edges of thearticle. The nonwoven portion of the backsheet may be provided onlywhere the leg gathers turn upward, such that the section of thebacksheet covering the core area is film.

Topsheet

The topsheet 50 in FIGS. 1-4 may be constructed from any one of a widerange of liquid and vapor permeable hydrophilic materials. The topsheetmay consist of or include non-woven webs of natural fibers (e.g., woodor cotton) or synthetic fibers (e.g., polypropylene or polyester), acombination of such webs or fibers, or apertured film. One suitabletopsheet material is a 15 gsm spunbond polypropylene from AvgolNon-wovens of Holon, Israel. In addition, the topsheet may be treatedwith a surfactant to facilitate liquid transfer, especially at a centralzone or area of the topsheet located over the core and an inner surfaceof the topsheet may be treated with a chemical to increase the surfacetension of liquids which pass through it.

In the embodiment of FIGS. 1-4, the topsheet 50 is formed from a singlepiece or sheet of material that covers substantially the entire area ofthe disposable absorbing article 10, including substantially all of thefront waist region 12, back waist region 14, and crotch region 16.Further, ear region 18 of disposable absorbent article 10 is formed fromthe same single topsheet material and, thus, may be referred to as beingunitary with and forming lateral extensions of the topsheet material.

Alternatively, the topsheet may be formed from multiple differentmaterials, which vary across the width of the topsheet. Such a multiplepiece design allows for the creation of preferred properties indifferent zones of the topsheet. For example, the topsheet may comprisea center section above the absorbent core that is made of a hydrophilicmaterial and a pair of leg cuff sections that are formed substantiallyfrom a hydrophobic material.

Absorbent Core

The absorbent core 46 of FIGS. 1-4 is generally centered about thelongitudinal axis AA and lateral axis BB of the diaper 10, and is firmlysecured between the topsheet 50 and the backsheet 40. The core 46 ispreferably made from any one of several compositions (known in the art)which are adapted to absorb bodily liquids received through the topsheet50. For example, the absorbent core may include a fluffed wood pulpcomponent which provides wicking capability and structural integrity,and a high absorbency material (e.g., super absorbent) for containingliquids. The core may also include additional additives to provide otherspecific properties such as baking soda to provide improved odorabsorbency. It should be noted, however, that the disposable absorbentarticle 10, according to the invention, is adapted to utilize absorbingcores of varying shapes and compositions.

Many absorbent cores known in the art are comprised of two components: ahigh absorbency material (or super absorbent material) and an absorbentcomposite. As expected, the majority of the volume of such an article(i.e., bulkiness) is due to the composite. The high absorbency materialmay be one of numerous compounds. A suitable material may includeinorganic materials such as polyvinyl alcohol, polyacrylates, variousgrafted starches, and cross linked polysodiumacrylate. Further, the highabsorbency material may be manufactured and utilized in the diaper innumerous forms including, but not limited to, particles, fibers, foams,and layers. On the other hand, the absorbent composite is generally acomposite material such as a defiberized fiber, or a wood pulp.

Another relatively new material for core composition is the “MicroThinAbsorbent Composite” under the “MegaThin” brand name. This material hasbeen developed by Japan Absorbent Technology Institute of Japan. Thematerial is a composite of SAP (superabsorbent polymer), MFC(microfibrillated cellulose) and non-woven which is characterized by itslighteners, thinners and softeners. See PCT Application PCT/JP97/04606,which is hereby incorporated by reference).

An application of any such material to the present structure accordingto the invention will be apparent to a person skilled in the art. Inaddition, the specific structural configuration of the disposableabsorbent article of the invention may also be manipulated to enhanceabsorbency (e.g., channels or grooves may be created to ultimatelydisperse liquid waste received in the deep containment).

Optional Layers

The disposable absorbent article according to the invention may containadditional layers including an acquisition layer or surge layer,preferably situated between the topsheet and the core. One function ofsuch an acquisition layer is to spread out or disperse liquid flow sothat liquid is distributed more evenly over the core surface. Thisserves to slow down the flow so that the liquid has adequate time to beabsorbed by the core. The acquisition layer also serves to prevent thecore from being saturated locally, while a substantial remainder of thecore is not absorbing any liquid.

Tape Tabs

The article must be secured to the wearer. This is most important withrespect to diapers since they are not pulled upon the wearer, liketraining pants, or incontinent briefs, but are fastened around thewearer. The securing elements compliment the elastic members byeffecting a quasi-seal between the wearer and the waist band and legcuffs, so that liquid is contained within the article which is thenabsorbed; in other words, so that it does not leak through gaps betweenthe wearer and the edge of the article. The securing elements may beadhesive, mechanical fasteners hook and loop features, or conceivablystrings, i.e., anything that will secure one end of the article to thelongitudinally opposite end.

In the adhesive devices shown in FIGS. 1, 2 and 4 above, the article 10is affixed to the wearer by tape fasteners 26 permanently affixed to(e.g., sewn directly into) the backsheet 40. The tape fasteners 26 arecontacted with the transversely opposite ear 22 extending from thebacksheet where they remain affixed due to an adhesive compound appliedto the fasteners 26.

The present inventive design of a disposable absorbent article is welladapted to carry out the diaper or other objects and attain the ends andadvantages previously mentioned, as well as others in that area. Whiledescription of a particular disposable diaper has been given for thepurpose of disclosure, numerous changes in the details of constructionof the diaper or other disposable absorbent article, in the arrangementof its part and in the steps of the process of manufacturing the articlemay be made. These changes will readily suggest themselves to thoseskilled in the art and are encompassed within the spirit of theinvention and the scope of the appended claims.

1-18. (Canceled)
 19. A disposable absorbent article having a pair oflongitudinally extending side edges and a pair of end edges extendingbetween said side edges, said article comprising: a topsheet layer; abacksheet layer; an absorbent core disposed between said topsheet andsaid backsheet; a pair of side walls, each of said side walls having apair of oppositely positioned end portions and an intermediate portiondisposed therebetween, wherein a first side wall is positioned generallybetween said core and one of said side edges and extends generally inthe longitudinal direction, and said other side wall is positionedgenerally between said core and said other side edge and extendsgenerally in the longitudinal direction; and a pair of end strips, eachof said end strips being fixed generally intermediate said core and oneof said end edges, and extending between said side edges, each of saidend strips including an elastic inward section spaced away from saidtopsheet and said absorbent core, each inward section having a pair ofside portions, each side portion being secured to an end portion of oneof said side walls, such that said side walls are biased generallyupwardly.
 20. The disposable absorbent article of claim 19, furthercomprising a containment pocket bounded by a substantially continuouscontainment wall disposed about said core, said side walls and saidelastic inward sections being disposed to form, at least partially, saidcontainment wall.
 21. The disposable absorbent article of claim 20,wherein each of said end strips further includes a fixed end sectionfixed substantially adjacent one of said end edges.
 22. The disposableabsorbent article of claim 21, wherein said fixed end section issubstantially elastic.
 23. The disposable absorbent article of claim 22,wherein each of said end strips further includes an intermediate sectiondisposed between said inward section and said fixed end section, saidintermediate section being substantially inelastic.
 24. The disposableabsorbent article of claim 23, wherein each of said end strips is formedfrom an elastic material, said intermediate section having a pluralityof voids adapted to substantially de-elasticize said intermediatesection.
 25. The disposable absorbent article of claim 20, wherein anintermediate portion of each of said side edges extending generallyparallel with said core is disposed in engagement with said sideportions of said elastic inward sections so as to be biased upwardly toform, at least partially, one of said sidewalls.
 26. The disposableabsorbent article of claim 20, wherein said side walls is formed by aportion of said topsheet and at least one elastic member securedthereto.
 27. The disposable absorbent article of claim 20, wherein saidpocket has a depth dimension defined as an average vertical distancebetween an inward edge of said inward section and an average elevationof said core, said depth dimension being greater than about ½″.
 28. Thedisposable absorbent article of claim 27, wherein said depth dimensionis between about ¾″ and about 2″. 29-36. (Canceled)
 37. The disposableabsorbent article of claim 19, wherein said article defines a frontwaist region adjacent one of said end edges, a back waist regionadjacent said other end edge, and a crotch region located between saidfront waist region and said back waist region, said core being disposedin said crotch region, said article further comprising an ear regionextending laterally from each side of each of said front waist regionand said back waist region, each one of said end strips extendingsubstantially laterally into one of said ear regions.
 38. A disposableabsorbent article having a pair of longitudinally extending side edgesand a pair of end edges defining a front waist region, a back waistregion, and a crotch region located between said front and back waistregions, said article comprising: a topsheet layer; a backsheet layer;an absorbent core disposed between said topsheet and said backsheet; anda containment pocket having a depth dimension, said pocket beingdisposed generally in said crotch region and bounded by a substantiallycontinuous containment wall that extends generally upwardly from saidtopsheet to retain exudates therein, said containment wall having atleast two elastic wall sections and at least two intermediate wallsections, each intermediate wall section being disposed between oneelastic wall section and another elastic wall section; and wherein eachof said elastic wall sections has a central portion and oppositelydisposed side portions and each of said intermediate wall sections hasoppositely disposed end portions, each of said side portions of saidelastic wall sections being secured to an end portion of one of saidintermediate wall sections such that said intermediate wall sections arebiased generally upwardly.
 39. The disposable absorbent article of claim38, further comprising an end strip secured generally to each one ofsaid waist regions, said end strip including an elastic inward sectionspaced away from said topsheet and said absorbent core, said elasticinward sections forming said elastic wall sections of said containmentwall.
 40. The disposable absorbent article of claim 39, wherein each ofsaid end strips includes a fixed end section fixed substantiallyadjacent one of said end edges. 41-44. (Canceled)
 45. The disposablearticle of claim 39, wherein each of said end strips is formed from anelastic material, said end strip further including a fixed section thatis substantially de-elasticized.
 46. The disposable absorbent article ofclaim 38, wherein an intermediate portion of each of said side edgesextending generally parallel with said core is disposed in engagementwith said side portions of said elastic wall sections so as to be biasedupwardly to form, at least partially, one of said intermediate wallsections.
 47. The disposable absorbent article of claim 38, wherein saidintermediate wall section is formed by a portion of said topsheet and atleast one elastic member secured thereto.
 48. The disposable absorbentarticle of claim 38, wherein said pocket has a depth dimension definedas an average vertical distance between an inward edge of said inwardsection and an average elevation of a top surface of said core, saiddepth dimension being greater than about ½″.
 49. The disposableabsorbent article of claim 38, wherein said depth dimension is betweenabout ½″ and about 4″.
 50. The disposable absorbent article of claim 38,wherein said depth dimension is between about ¾″ and about 2″.
 51. Thedisposable absorbent article of claim 38, wherein said elastic wallsections are formed from a substantially elastic material.
 52. Thedisposable absorbent article of claim 51, wherein said elastic wallsection is distinct from said topsheet.
 53. The disposable absorbentarticle of claim 38, wherein each of said elastic wall sections isformed, at least partially, by a portion of said topsheet. 54-67.(Canceled)
 68. A disposable absorbent article having a pair oflongitudinally extending side edges and a pair of end edges extendingbetween said side edges, said article comprising: a topsheet layer; abacksheet layer; an absorbent core disposed between said topsheet andsaid backsheet; positioned end portions and an intermediate portiondisposed therebetween, wherein a first side wall is positioned generallybetween said core and one of said side edges and extends generally inthe longitudinal direction, and said other side wall is positionedgenerally between said core and said other side edge and extendsgenerally in the longitudinal direction; and a pair of elastic endwalls, each elastic end wall extending from one of said side walls tosaid other side wall and being secured to an end portion of each of saidside walls to bias said side walls generally upwardly.
 69. Thedisposable absorbent article of claim 68, further comprising acontainment pocket bounded by a continuous containment wall disposedabout said core, disposed to form said containment wall being formed bysaid side walls and said elastic end walls.
 70. The disposable absorbentarticle of claim 69, wherein said side walls is formed by a portion ofsaid topsheet and at least one elastic member secured thereto.
 71. Thedisposable absorbent article of claim 69, wherein said pocket has adepth dimension defined as an average vertical distance between aninward edge of said inward section and an average elevation of saidcore, said depth dimension being greater than about ½″.
 72. Thedisposable absorbent article of claim 71, wherein said depth dimensionis between about ¾″ and about 2″.
 73. The disposable absorbent articleof claim 69, wherein an intermediate portion of each of said side edgesis disposed in engagement with each of said elastic end walls so as tobe biased upwardly to form, at least partially, one of said side walls.74. The disposable absorbent article of claim 73, wherein said side wallis formed by a portion of said topsheet and at least one elastic membersecured thereto.
 75. The disposable absorbent article of claim 68,wherein said elastic end wall is formed from a substantially elasticmaterial.